International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2073

Real Time Industrial Monitoring System
Rahul D. Chavhan
#1
, Sachin U. Chavhan
#2
, Ganesh B. Chavan
#3

#1
Assistant Professor, Department of Electronics & Telecommunication, SGBA University, Amaravati
JCOET, Arni Road, Kinhi, Yavatmal, Maharashtra, INDIA
#2
Assistant Professor, Department of Electronics & Telecommunication, University of Pune, Pune
SFs SIEM, Maihiravani, Nashik, Maharashtra, INDIA
#3
Assistant Professor, Computer Engineering, North Maharashtra University, Jalgaon
GFs GCOE, Bhusaval Road, Jalgaon, Maharashtra, INDIA



Abstract Industries are the biggest workplace all over the
world, also there are large number of peoples involves as a
worker and most of them are work as a machine operator. There
are many systems developed for industrial work place, some of
them, monitors machine processes and some do monitoring and
control of machine parameters. Such as speed, temperature,
production batch count etc. However there is no such system
available that provides monitoring of operator during their
work is in progress at workplace. This paper proposes the
monitoring of the operators and the machines, by Real time
Operator -Machine Allocation and monitoring system
(Omams). Omams allocates a work machine to worker at entry
point itself. It uses automation with RFID and one of the
standards of wireless communication method. The system can be
industry specific. Through this research paper our approach is
to make fair allocation of machine to the operator in industry
and reduce hassle for efficiency calculations.
KeywordsReal Time Monitoring, RFID, Operator Allotment,
Monitoring System, Machine Allocation.

I. INTRODUCTION
The focus of proposed system is real time monitoring of
operator in workshop which is necessary for any industrial
management. In recent years the focus was on machine
parameter monitoring; now we are trying to design a system
which is beneficial to the operators and management
personnel by providing them information about machine
utilization.
A. Industrial Operation
In any industry, there are many departments. Each
department may have many separate workshops. For each
workshop, there may be maximum three shifts in a day.
During the shift change, operators working in the
workplace are relieved and entering the workplace is
allocated the machines. In this case study we are trying to
provide automated allocation and monitoring of operator at
work place.
Normally every industry keeps two entries of the workers.
First is at the entry gate of company (i.e. the time office or
Personnel department) and second is at workshop
supervisor register of individual worker. One is kept for
salary and work hours count and later is kept for
production floor monitoring or efficiency monitoring.
B. Radio Frequency Identification
Radio-frequency identification (RFID) is the wireless non-
contact use of radio-frequency electromagnetic fields to
transfer data, for the purposes of automatically identifying and
tracking tags attached to objects. The tags contain
electronically stored information. Unlike a bar code, the tag
does not necessarily need to be within line of sight of the
reader, and may be embedded in the tracked object [1]. The
radio frequency identification (RFID) is the technology
similar in theory to bar code identification. With RFID, the
electromagnetic or electrostatic coupling in the RF portion of
the electromagnetic spectrum is used to transmit signals. An
RFID system consists of an antenna and a transceiver, which
read the radio frequency and transfer the information to a
processing device, and a transponder, or tag, which is
an integrated circuit containing the RF circuitry and
information to be transmitted. The key differences between
RFID and bar code technology are RFID eliminates the need
for line-of-sight reading that bar coding depends on. Also,
RFID scanning can be done at greater distances than bar code
scanning. High frequency RFID systems (850 MHz to 950
MHz and 2.4 GHz to 2.5 GHz) offer transmission ranges of
more than 90 feet, although wavelengths in the 2.4 GHz range
are absorbed by water (the human body) and therefore has
limitations. RFID is also called dedicated short range
communication (DSRC) [2]. An RFID readers function is to
interrogate RFID tags. The means of interrogation is wireless
and because the distance is relatively short; line of sight
between the reader and tags is not necessary. A
reader contains an RF module, which acts as both a
transmitter and receiver of radio frequency signals [3].
II. RELATED WORK

In the current scenario of Industry, the research work was
carried on monitoring and control of parameters such as real
time production monitoring; a production monitoring is a
International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2074

system that is used in real time to record production line
problems. It is constructed using programmable logic
controller and sensors to collect data from production lines [4],
real time monitoring of an industrial batch process, the
process shares many similarities with other batch processes in
that cycle times can vary considerably, instrumentation is
limited and inefficient laboratory assays are required to
determine the end-point of each batch [5], real time
monitoring of complex industrial process with particle filters,
the application of particle filtering algorithms to fault
diagnosis in complex industrial processes [6], wireless
monitoring and control of networks [7], wireless sensors for
monitoring workers health, a wireless/mobile sensor
framework: to estimate production efficiency through remote
physiological monitoring in all conditions; to suggest effective
work schedules according to individual physiological
conditions; to propose safety guidelines for tradesmen; and to
validate the production efficiency in the construction industry
[8], adaptive real time monitoring for large scale networked
system monitoring, it is continuous real-time monitoring,
which is essential for the realization of adaptive management
systems in large-scale dynamic environments. Real time
monitoring provides the necessary input to the decision
making process of network management [9], monitoring
industrial energy and carbon flow [10], etc. The research work
has either focus of technical parameter of machine/processes
or of data and security monitoring of health and environment.
In our system we are monitoring the operator
throughout working hours by allotting the operator to the
specific machine by using different modules.
III. PROBLEMS IN CURRENT SYSTEM

There are many problems and issues remains unresolved in
current model of work distribution and work monitoring. To
enlist a few are as below:
1. There should be one supervisor to record or monitor entry
and exit time and one at job allocation point to allocate a duty to
the operator.
2. The production floor supervisor is assumed as 100% fact
known person for the production floor.
3. Less exposure of technology, for example supervisor
allots all operators to duty; workers dont have any information
about it.
4. Manual monitoring is required; no one understands machine
utilization except supervisor.
5. There may be fake allotment of machine to operator by
supervisor.
6. Two point registrations consume valuable work time and
hence decreased efficiency.
7. Manual recordkeeping cannot be accurate all the time.
These problems are observed from case study on industrial
shift change process. In proposed systems the management
issue and technical issues are resolved by combination of
two technologies, RFID, wireless network and automation
software. It can be a great help for monitoring of operators,
machines and management.
IV. PROPOSED MODEL

Our proposed model is an attempt to solve above problems
with the help of Real time industrial operator monitoring
system. It uses RFID to identify the worker and automation
of the system.
The system will have three main components:
1. Scan-In unit
2. Central unit
3. Scan- Out unit
One of the wireless standards methods can be used for
connectivity between Scan-In/ Scan-Out Unit and Central
Unit.

Fig. 1 Architecture of System
Through this research work we are attempting to propose
model which minimizes the problem of allotment. Moreover
transparency in the system comes with the use of
technology. In this model we have enhanced the use of RFID
with communication Network. The radio frequency
identification (RFID) is unique identity for an employee, which
can be easily detected with the help of RFID reader.
Therefore we have suggested the use of embedded system for
scanning and allotting the machine to the operator.


V. METHODOLOGY

Our proposed model is divided in the following sub-module.
(A) In.
(B) Out.
International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2075

(C) Allocation Procedure.
In an attempt with the Industry our proposed Model suggest
the use of RFID in the employee card, which contains the
code, for example A24564 is operator specific and identify
the operator from whom the Code is extracted. A sample of
RFID tag image is given in the following Figure 1.

Fig. 2 Sample of a RFID on a Card.
So the steps in above proceedings in operator viewpoints are:-
A. In

The scan in unit serves two purposes in the system; first it
will recognize the authenticated workmen for the industry.
Second it will deliver a note or machine number for work
along with job allocation.
Each employee has been given an identity card with a
unique RFID.

Fig. 3 Process of Check-In
1. Operator must produce his card at Scan-In unit to check-In.
It facilitates faster scanning of employee code and avoids
queuing at entry point.
2. Operator places his card in his hand near Scan-In unit to
read RFID to get in.
3. A Scan-In unit reads the RFID over the card of operator
and verifies it.
4. After In process the information is sent to the central unit
for allotment.
B. Out

1. Operator goes to the Scan-Out terminal and scans its RFID to
get out.

Fig. 4 Process of Check-Out
2. A Scan-Out unit reads the RFID over the card of operator
and verifies it.
3. After Out process the information sent to the central unit for
further process.
Once the Out procedure is done by the scan-out unit, the
operator completes his work and leaves the workshop. But
if the oper ator left the wor k in-between due to his
personal reason then the scan-out unit will allow the operator
to scan his RFID and it will send the information to central unit
for allocation of machine to other operator.
C. Allotment

After getting information from scan-in unit and scan-out unit
the central unit starts the procedure of allotment.
1. Get the list of operators who are checking-in from scan-in
unit.
2. Get the list operators who are checking-out from scan-out
unit.
3. Check the vacant machine list and allot the machine to
the operators who are checking-in.
4. Check for operators who are not allotted and display a list
of those with allotted operators list.
5. If in between any operator leaves the work, the machine
he operating is allotted to the operator who is in waiting list.
For any monitoring application in industry, there are
many parameters to be handled. In this system we are
concentrating on machine operator. The operators are
provided a unique code for this purpose. For monitoring
operators and allotting them a specific machine, there are two
registration units, one is at entry of industry i.e. Scan-In unit
and other is in workshop i.e. Scan-Out unit. Both units are
identical. These units may be located fixed at a specific
location. Both the units scan the operators code and allow
them to enter and exit. Their unique numbers are then sent to
the central unit continuously from both places i.e. Scan-In unit
& Scan-Out Unit. The list from scan-in unit is of operators
who are coming to work and from scan-out unit is of operators
who are going from work. The central unit receives the data
International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2076

from both the units and allots a machine to each operator
sequentially who check-in from scan-in unit and relieve the
operator who check-out from scan-out unit, sends the
corresponding information to display. There are two identical
display units displaying the same information, one placed at
workshop and other is at managers office along with central
unit. This cyclic process is continued till our requirement is
fulfilled during shift change.
Whenever the number of operators exceeds the number of
machines, central unit displays a waiting the list of remaining
operators on the display. If numbers of operators are less than
number of machine, then central unit displays the list of
vacant machine. If in between any operator left the machine,
due to some problem, he has to scan his card at Scan-Out unit
for check-out at workshop. After check-out, Scan-Out unit
sends this information to the central unit and then central unit
assigns a next operator waiting for work by displaying this
information at display unit automatically. The system provides
a complete monitoring of operators and makes it more
transparent.

VI. BENEFITS

1. This technology will replace the complex
shift changing procedure that is often carried by the
industry.
2. Induction of this technology will facilitate supervisor to
allot vacant machine operators.
3. It will enable operator to update the status of his turning up
for the work.
4. After this updating, central unit will come to know about
the machine of absent operator and will allot those machine
waiting operator informing them by displaying or an SMS.
5. After allotting the machines to all the operators, if some
machine still remains vacant then it will be reflected as
available machine on the display and it could be allotted to
operator which is willing to work for that machine from any of
the workshop.
6. It attempts to reserve each and every machine even
vacant for an hour.
7. It maintains the transparency in machine allocation and
makes the shift changing process fast.


VII. EXPERIMENTAL RESULTS

For experiment and trials, the scan in and scan out units are
designed with LPC2148 ARM7TDMI processor, the central
processing unit is designed in same manner.
In scan and central unit, we used interfacing of GSM SIM900
module for communication between scan unit and central unit.
It uses GPRS for data sharing which provides secure data
sharing between these units. The scan unit is also using the
RFID reader for identifying the operator and scanning operator
id.
SIM900 is a quad-band GSM/GPRS engine that works on
frequencies GSM 850MHz, EGSM 900MHz, DCS 1800MHz
and PCS 1900MHz. It gives the GPRS data downlink transfer:
max. 85.6 kbps and GPRS data uplink transfer: max. 42.8
kbps speed. For communication between units, GSM wireless
method had been implementing and gives security and
required speed of data transfer with satisfying results. Fig. 2,
Fig. 3 and Fig. 4 shows the experimental setup performed.


Fig. 5 Scan-In Unit

Fig. 6 Scan-Out Unit
International Journal of Computer Trends and Technology (IJCTT) volume 4 Issue 7July 2013

ISSN: 2231-2803 http://www.ijcttjournal.org Page 2077


Fig.7 Central Unit

VIII. CONCLUSION

This model proposes radical change in industrial operation and
operator experience. Scan-in units are provided to workshop
supervisor for smooth and faster scanning and verification of
operators. RFID is embedded in the cards and this RFID is
scanned by scan-in unit and scan-out unit. In RFID, an
operator specific code is stored. When scanning unit encodes
this code by In process or Out process, it redirects to
central unit. In process updates the information of all
operators available in the industry and let the central unit to
make the machine reserve or vacant. Central unit allot the
machines operators and if still some machines remain vacant
then reflect them as available across industry from where any
operator willing to work on it and can take that
machi ne. Apart from this In, Out and allotment process is
also provided to the operators. Out process provides the
operators to break his work at any situation by Out procedure
and at the same time, his vacant machine are provided to a
waitlisted operator. These interfaces provide capability to
work at any machine within the industry. These
technology inclusions in the industry bring transparency and
reduce the hassles of workers while shift change.

ACKNOWLEDGEMENT

The authors would like to thank Dr. K. P. Rane, H.O.D.
E&TC Dept., Godavari Foundations Godavari COE, Jalgaon,
for their kind support and Dr. B. K. Mukharjee, Principal,
Godavari Foundations Godavari College of Engineering,
Jalgaon, for his encouragement and inspiration to work on this
current research topic. They also would like to thank Prof. P.
V. Phalak, Vice Principal, GFs GCOE, Jalgaon, for making
software required and laboratory available.

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